Director of Manufacturing

XPEL; San Antonio (TX); On-site; USD 180,000 - 280,000; Full time

Job summary

XPEL is seeking a Director of Manufacturing to lead the technical strategy and operations for producing our paint protection film products. You will oversee roll-to-roll coating, lamination, slitting and converting, with a focus on TPU films, while shaping the film structure, adhesives and surface topcoats.

You will drive process optimization, quality, and capacity across internal operations and external partners, mentoring engineers and coordinating with R&D and Product Management to scale new

Qualifications

• Bachelor's degree in a technical field (Chemical/Materials/Polymer/Mechanical).
• 10+ years manufacturing or process engineering experience in coatings or films.
• 5+ years leading technical or multi-functional teams at director/manager level.
• Experience with contract manufacturers, toll coaters, converters or key suppliers.

Responsibilities

• Provide technical leadership over roll-to-roll coating, lamination, slitting and converting processes for TPU-based PPF films.
• Serve as technical authority on PPF film structure, including adhesives and topcoats.
• Evaluate and optimize coating processes to meet coat weight, appearance and performance requirements.
• Lead root-cause analysis on coating, adhesive and film defects and drive corrective actions.
• Oversee network of coating and manufacturing partners to ensure quality and capacity for growth.
• Lead onboarding of new partners with process specs, audits and capability studies.
• Collaborate with R&D and Product Management to move new products from lab to production.
• Drive Lean, Six Sigma, SPC and continuous improvement to reduce variation and improve yield and on-time delivery.

Skills

Leadership

Cross-functional collaboration

Communication

Problem solving

Travel readiness

Education

Bachelor's degree in Chemical Engineering

Bachelor's degree in Materials Science

Bachelor's degree in Polymer Science

Bachelor's degree in Mechanical Engineering

Tools

ERP/MES systems

DOE

SPC

FMEA

Job description

Job Summary:

The Director of Manufacturing is XPEL’s senior technical leader for how our paint protection film (PPF) products are produced.

Core Duties

• Provide technical leadership over roll-to-roll coating, lamination, slitting and converting processes for XPEL’s paint protection film products, with a focus on TPU-based films.
• Serve as XPEL’s technical authority on the PPF film structure, including self-healing and protective topcoats, pressure-sensitive adhesives, primers and release liners.
• Evaluate and optimize coating processes (such as slot-die, gravure and similar methods) to meet each product’s coat weight, appearance and performance requirements.
• Guide best practices in drying, curing and web handling to ensure consistent, repeatable production.
• Ensure products consistently meet specifications for clarity, gloss, thickness, adhesion, self-healing, stain and yellowing resistance, conformability and long-term weathering performance.
• Lead root-cause analysis and corrective action on coating, adhesive and film defects, and connect field performance and installer feedback to process and material causes.
• Provide technical oversight of XPEL’s network of coating, converting and manufacturing partners to ensure processes, quality and capacity support company growth.
• Lead technical qualification and onboarding of new partners, including process specifications, quality agreements, trial runs, capability studies, scorecards and audits.
• Work with Procurement and Quality on raw-material specifications (TPU film, resins, adhesives, liners), incoming inspection and supplier corrective actions, with focus on lot-to-lot variation.
• Partner with R&D and Product Management to move new PPF products from lab and pilot scale to full production, including DOE, capability validation and product qualification.
• Drive Lean, Six Sigma, SPC and related continuous improvement practices to reduce variation and improve yield, scrap, throughput, OEE and on-time delivery.
• Establish change control, process documentation (SOPs, work instructions, recipes) and FMEA/PFMEA practices across coating and converting operations.
• Build and develop a team of process and manufacturing engineers and serve as a technical mentor across XPEL and its partner network.
• Additional duties as assigned by leadership.

Basic Qualifications

• Bachelor’s degree in Chemical Engineering, Materials Science, Polymer Science, Mechanical Engineering or a related technical field.
• 10+ years of manufacturing or process engineering experience, including roll-to-roll coating, laminating, extrusion or converting of films, coated materials or other flexible substrates.
• 5+ years leading technical or multi-functional teams at the manager or director level.
• Experience working with contract manufacturers, toll coaters, converters or key suppliers.
• Track record of delivering measurable improvements in quality, yield and throughput.
• Solid understanding of coating processes, drying and curing, web handling and lamination.
• Knowledge of polymer films (TPU preferred), adhesive systems and coating chemistries.
• Experience developing and enforcing product and process specifications, and with film testing methods such as adhesion, peel, gloss, thickness and weathering.
• Working knowledge of SPC, DOE, structured root-cause analysis (8D, 5-Why, Fishbone) and FMEA.
• Familiarity with ISO 9001 and/or IATF 16949 quality systems and EHS practices for coating operations.
• Experience with ERP/MES systems and production data analytics.
• Excellent communication skills with executives, R&D, partners, suppliers and production teams, with the ability to influence without direct authority.
• Ability to travel up to 50%, including internationally.

Desired Qualifications

• Advanced degree in a technical discipline
• Experience with paint protection film, TPU films or automotive exterior films and coatings
• Experience in related industries such as automotive, adhesive tapes and labels, flexible packaging or coated materials
• Lean Six Sigma Green/Black Belt or PMP certification

XPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.